Building panel



Sept. 14, 1943. E. s. HARMAN BUILDING PANEL Fi led Oct. 2, 1940 2 Sheets$heet 1 .TJVEHLQI" 'Eugene SH arm cm- Sept. 14, 1943. E. s. HARMAN BUILDING PANEL Filed Oct. 2, 1940 2 Sheets-Sheet 2 171/ an CJI" [agape J: flcuman Patented Sept. 14, 1943 UNITED STATES PATENT. OFFICE BUILDING PANEL Eugene S. Harman, Chicago, Ill.

Application October 2, 1940, Serial No. 359,307

11 Claims. (01. 72-23) This invention relates to a building panel and to a method of assembling the same. More particularly, the invention relates to a building unit that can be partially or completely prefabricated and then assembled in the field to form a wall or roof structure.

It has heretofore been proposed to provide brick or tile veneered building units having a backing of composition board. Such units, however, are usually employed only over wood siding, since they are not sufliciently substantial to afford the desired protection by themselves. Moreover, the panels close to the ground level are subject to deterioration and decay due to the attack of moisture, fungi or insects.

Brick or tile panels on expanded metal alone, without any backing, are in current use for remodeling purposes but are not suitable for new construction. They are not sufliciently rigid or strong to make it feasible to prefabricate such panels and ship them long distances to the point of use.

Steel siding in cheap form has been used, but not satisfactorily, owing to the crackling sounds caused by the expansion and contraction of the sheet metal. on the other hand, corrugated steel sheets and steel panels which provide for expansion, may be used only for industrial building, since they are not suited for homes and dwellings where appearance is a factor.

In accordance with my present invention, I provide building panels or units of veneered construction, having an embossed sheet metal backing and a facing simulating brick, tile or other masonry, secured to the backing in such a way that the facing is relatively unaifected by the expansion and contraction of the sheet metal backing. This is accomplished by the use of expanded metal lath, or similar keying material, and by securing such keying material to embossed or raised portions of the metal backing at properly spaced intervals. Where metal lath is used, the lath is spot welded to the raised or embossed portions of the backing sheet at intervals so spaced and arranged as to permit freedom of expansion and contraction of the backing sheet without causing the facing material to crack. The facing material, although keyed to the metal lath, is not surface bonded to the backing sheet,

that can be either completely or partially prefabricated, and which employs an embossed metal backing sheet to impart to the panel or unit sufilcient rigidity to enable the same to be used in new construction as a structural wall or roof unit.

It is a further important object of this invention to provide a prefabricated wall or roof panel of a veneered construction that simulates masonry and that may be manufactured and installed at a considerable saving, as compared with the costof the usual masonry wall construction, and that will have a relatively long life, with freedom from such troubles as cracldng, corrosion or other usual form of deterioration.

It is a further important object of this invention to provide a method of assembling building units or panels to form walls or roofs simulating the appearance of masonry walls, tiled roots, or the like.

Other and further important objects of this invention will become apparent from the following description and the accompanying drawings.

This invention (in a preferred form) is illustrated in the drawings and hereinafter more fully described.

On the drawings:

Figure 1 is a fragmentary plan view of an assembly of a plurality of building panels or units embodying my invention.

Figure 2 is an enlarged fragmentary sectional view taken substantially along the line IIII of Fig. 1'.

Figure 3 is an enlarged fragmentary sectional view taken substantially along the line III-III of Fig. 1.

Figure 4 is a fragmentary plan view of a plurality of building panels or units of slightly modifled construction. I

Figure 5 is a fragmentary view of the reverse side from that illustrated in Fig. 1.

Figure 6 is a fragmentary view, similar to that of Fig. 5, but showing a marginal portion of a building panel or unit.

Figure 7 is an enlarged sectional view taken substantially along the line VII-VII of Fig. 4.

Figure 8 is a fragmentary enlarged sectional view taken substantially along the line VIII-VIII of Fig. 6.

Figure 9 is an enlarged fragmentary sectional view taken substantially along the line IX-QL of Fig. 8.

Figure 10 is an enlarged fragmentary sectional gew taken substantially along the line XX of Figure 12 is a fragmentary plan view of a modified form of my invention, illustrating a building panel or unit for use in roofing construction.

Figure 13 is a fragmentary plan view of the reverse side of the backing sheet illustrated in Fig. 12.

Figure 14 is an enlarged fragmentary sectional view taken substantially along the line XIV-XIV of Fig. 12.

As shown on the drawingsr The reference numeral 20 (Figs. 1 to 11 inelusive) indicates an embossed sheet metal backing plate. Each backing plate 20, as best illustrated in Fig. 11, may suitably be embossed with a regular design, such as a design simulating bricks or other masonry unit. The surface viewed in Fig. 11 comprises longitudinally extending ridges or raised portions 2| with staggered, transverse, raised portions 22 connecting the adjacent ridges 2| to define depressed areas 23 that are rectangular in shape. Viewed from the reverse side, the rectangular shaped areas 23 would, of course, stand out in relief and the narrow strips 2| and 22 would be depressed, forming grooves about the raised, rectangular areas. Thus, the reverse surface from that shown in Fig. 11 would somewhat simulate a brick wall and it is that surface that has heretofore constituted the external face when this type of embossed sheet metal has been used for building wall construction. If large plates 20 are used, angles or other reinforcing ribs can be spot welded to the back faces of the plates at suitable intervals to stiffen the plates. When the plates are secured together to form a wall, splicing ribs can join the ends of aligned reinforcing ribs of angles.

In accordance with the present invention, expanded metal lath 24 is applied over the obverse surface of each panel 20, as viewed in Fig. 11, and is spot welded thereto at spaced points, such as indicated by the reference numeral 25- (Figs. 1 to 4 inclusive). Preferably, the points at which spot welding is done, are spaced along the raised strips or ridges 2| and 22 at approximately their intersections, as indicated by the dotted circles S in Figs. and 6.

After the expanded metal lath- 24 has been spot welded in place to a backing plate 20, the assembly is rendered corrosionproof in some suitable way, as by parkerizing, or bonderizing, and then coating all exposed surfaces with a synthetic resin varnish, such as Bakelite. Itis important to protect the surfaces of the panel against corrosion, since otherwise the surfaces would be likely to rust and become corroded away, a condition that is not conductive to maintaining a good bond between the expanded metal lath and the sheet metal backing plate, or between the expanded metal lath and the facing material to be keyed thereto.

The facing material that is applied over the metal lath and keyed thereto may be stucco, or, preferably, cementitious material molded in the form of bricks 26, or other masonry unit. As illustrated in Figs. 1 to 3 inclusive, the facing blocks 26 are relatively thin and extend through the metal lath, expanded metal, metal netting or other reticular material 24 into contact with the surface of the backing plate 20. The veneer blocks 26 are thus keyed to the metal lath 24 but there is no surface bond between said blocks and the backing plate 20. It will also be noted that the blocks 26, although conforming in general with the depressed areas 23, are of smaller dimension, so that the lateral edges of the blocks 26 do not extend into direct contact with the raised strips or ridges 2| or 22. Since the expansion and contraction of the sheet metal backing plate 20 is compensated forat the raised strips or ridges 2| and 22, the blocks 26 are not subjected to any appreciable stress by virtue of the unequal coeillcientsof expansion between the metal of the backing plate and the cementitious composition of the blocks 26. This is a very important feature of my invention.

A convenient way to mold the facing material, or blocks 26, is to use a backing plate 20 as the bottom of a mold, into which the plastic, cemetitious composition forming the blocks 26 is poured. On top of the backing sheet may be placed a cellular form provided with openings of the size of the blocks 26 that are to be molded, the depth of the form corresponding with the thickness of the blocks 26 above the expanded metal lath 24. The weight of the cellular form will hold the expanded metal lath 24 substantially against the surface of the backing plate 20, so that there is little, if any, spreading out of the poured cementitious material beneath the parti-' tions of the cellular form.

After the blocks 26 have set, the cellular form is removed, thereby leaving spaces 21 between the adjacent blocks. These spaces 2! are filled with mortar 23, or other joint sealing material, at the time the building units or panels are assembled to form a wall or roof construction.

In order to facilitate the assembly of the building panels or units, each of the backing sheets 20 is provided along two of its adjacent margins with flanges 23 and 30 (Fig. 11). Said flanges 29 are notched at regular intervals, as at 3|, in order to enable the operator by means of a simple instrument, such as a pair of broad pliers, to turn the flanges 29 over shallower straight flanges 32' of an adjoining panel (Fig. 2). Similarly, the notched flanges 30 are adapted to be bent over straight flanges 33 of an adjacent panel or building unit (Fig. 7). In addition to crimping the flanges 29 and 30 over the straight flanges 32 and 33, these may be spot welded in place to insure permanency of assemblage.

Wherefour building panels or units meet, as in Figs. 5 and 10, a reinforcing clip 34 may be employed, which has U-shaped legs 35 and 36 for enclosing the flanges of the backing plate. In addition to effecting a tight clamping fit between the legs of the reinforcing clip 34 and the backing plate flanges, the clip may be spot welded, as at 31, to the backing plate flanges.

Where but two backing plates 211 meet, as at an end of a wall construction, as shown in Figs. 6, 8 and 9, an angle member 38 is secured to the adjacent backing plate 20 by means of a flange 39, notched as at 40, to straddle the cut-down portion 41 of the backing plate flanges 29 and 32.

In the assembly of veneered panels illustrated in Fig. l, the dotted line 42 indicates the line of joinder between adjacent panels. With the blocks 26 arranged in staggered alignment, similar to bricks, it would be necessary either to split blocks, such as the blocks 43 along the division line 42, or else, as there shown, to insert the block 43 as a separate unit after the assemblage block is provided with pins 44 at its opposite end for engagement with tongues 45 struck up from the base plate 20. The expanded metal lath 24 is cut away to define the space for receiving the block 43, but after the block is in place, mortar or Each block 43 is thus securely held in place and the division line 42 entirely concealed.

In an alternative form of construction illustrated in Fig. 4, each 01' th bricks or other masonry blocks 45 is provided with vertically extended scores 45 so as to conceal, or at least make less conspicuous, the division line 41 between the halves of the bricks 45, which in this case is split at the junction line 48 between adjacent panels. The other building blocks or veneer bricks 48 may be similarly scored for the sake of uniformity, but this is not necessary.

The veneered panels illustrated in Figs. 1 to 4 inclusive are more specifically intended for use in wall construction to simulate brick or other masonry walls. In Figs. 12 to 14 inclusive, however, I have illustrated a slightly modified form of panel construction which is adapted for use in As illustrated in Figs. 12 to 14 inclusive, a sheet metal backing plate 50 is provided with square shaped embossed portions joined by depressed linear portions 52 viewed as in Fig. 13. To the reverse side from that shown in Fig. 13, which is the observe side in Fig. 12, is secured expanded metal lath 53. I

The expanded metal lath is spot welded, as at 54, to embossed circular portions 55 centrally positioned in the square shaped areas 5|. Said raised portions, or bosses 55, are of substantially the same height as the ridges, so that the expanded metal lath 53 lies in contact with both the bosses and the intersecting ridges. The lath may also be spot welded to the ridges, as at 56.

Cementitious material is poured onto the metal lath, in the same manner as previously described, to form blocks 51, which extend into and conform generally with the square shaped depressed areas 5|. The spaces between the blocks 51 are filled, preferably, with a permanently plastic material such as asphalt, or other waterproof mastic material 58 to form a finished veneered panel 59. The plastic permits deflection of the steel sheets without cracking the cement.

Steel roof panels such as the veneered panel 59 may be usedon steel buildings, where lightness of construction, fireproofness and appearance are important factors. It is particularly well adapted for prefabricated steel buildings, airplane hangars, barracks, and industrial buildings. The steel deck, if the grooved joints are Protected with a strip of tarred roof felt, will be water tight when laid with a slight pitch. The cement tile over the steel sheet affords additional weather proofing, as well as a neat appearance. Additional insulation desirable for residential purposes may be provided by applying insulation to the underside of the steel deck. Expansion is provided for by the embossing.

It should be understood that the building units of this invention can be fabricated and shipped to the construction job without the cementitious material keyed thereon. Thus, the metal units per se can be covered with the cementitious finishing surface at the construction job. In some instances it may be feasible to erect the metal units as side walls and roof of a building and then apply the cementitious material such as stucco to the side walls and scored concrete on the roof of the erected building.

It will, of course, be understood that various details of construction may be varied through a wide range without departing from the principles of this invention and it is, therefore, not the purpose to limit the patent granted hereon otherwise than necessitated by the scope of the appended claims.

I claim as my invention:

1. A building unit comprising an embossed sheet metal backing plate having a regular pattern of intersecting raised portions, foraminous metal keying material secured at spaced intervals to the raised embossed portions of said backing plate, and cementitious material arranged in separate blocks conforming to said embossed pattern and keyed to said keying material but spaced from said raised portions, whereby expansion and contraction of said backing plate may be compensated for at said embossed portions without causing said cementitious material to crack.

2. A building unit comprising an embossed sheet metal backing plate having a regular pattern of intersecting raised portions, foraminous metal keying material secured at spaced intervals to the raised embossed portions of said backing plate, cementitious material arranged in separate blocks conforming to said embossed pattern and keyed to said keying material :but spaced from said raised portions, whereby expansion and contraction of said backing plate may be compensated for at said embossed portions without causing said cementitious material to crack and sealing material disposed in the interspaces between said blocks.

3. A building unit comprising a sheet metal backing having intersecting embossed portions of regular pattern, expanded metal lath spot welded to said embossed portions, spaced blocks of relatively thin cementitious material arranged within areas defined by said embossed portions in conformance with said pattern and keyed to said metal lath, and material keyed to said metal lath filling and sealing. said spaces between adjacent blocks.

4. A building unit comprising a sheet metal backing having-intersecting embossed portions of regular pattern, expanded metal lath spot welded to said embossed portions, spaced blocks of relatively thin cementitious material arranged within areas defined by said embossed portions in conformance with said pattern and keyed to said metal lath, and permanently plastic material keyed to said metal lath filling and sealing said spaces between adjacent blocks.

5. A building unit comprising a sheet metal backing plate embossed to simulate masonry blocks on one face thereby providing intersecting raised linear portions on the other-face, expanded metal lath spot welded to said raised portions on the other face of said backing plate, relatively thin blocks of cementitious material keyed to said metal lath and positioned within the areas defined by said raised portion but out of direct contact with the raised portions, and sealing material keyed to said lath in the spaces between said blocks.

6. A building unit comprising a sheet metal backing plate embossed to simulate masonry blocks on one face thereby providing intersecting raised linear portions on the other face, expanded metal lath spot welded to said raised portions on the other face of said backing plate, relatively thin blocks of cementitious material keyed to said metal lath and positioned within the areas defined by said raised portions but out of direct contact with the raised portions, and permanently plastic sealing material keyed to said lath in the spaces between said blocks.

,7. A prefabricated building panel of veneered construction, comprising a sheet metal backing plate bearing an embossed design and having notched dependent flanges along at least two edges, metal lath spot welded to said backing plate at spaced raised portions thereof, composition material keyed to said metal lath arranged in blocks conforming to said embossed design and Joint filling material keyed to said metal lath and forming joints between said blocks,

8. A prefabricated building panel of veneered construction, comprising a sheet metal backing plate having an embossed design therein, expanded metal lath spot welded to embossed portions of said backing plate, said backing plate and metal lath being coated to protect the same raised strips defining a plurality of spaced depressed areas and expanded metal lath spot welded to raised portions of the backing plate adapted to key the cementltious material, said sheet adapted to expand and contract between the depressed areas without cracking the cementitious material. 4 10. A building unit comprising a backing plate having raised ridges defining a plurality of flat depressed areas therebetween, reticular metal material secured to said ridges, and blocks of cementitious material keyed to said reticular metal material and extending therethrough into contact with said flat areas in spaced relationship to said raised ridges.

11. A prefabricated building panel comprising a sheet metal backing having raised portions alternating with depressed portions, keying material secured to said raised portions, cementltious material keyed to said keying material exclusively over said depressed portions and plastic material disposed over said raised portions, whereby expansion and contraction of said panel is largely limited to said raised portions and to said plastic material.

' EUGENE 8. HARMAN. 

